Toro 30605 User manual

(Models 30603, 30605, 30607 and 30609)

Part No. 13202SL

Service Manual

Groundsmaster

R

4000--D & 4010--D

Preface

The purpose of this publication is to provide the service

technician with information for troubleshooting, testing

and repair of major systems and components on the

Groundsmaster 4000--D (Models 30605 and 30609)

and Groundsmaster 4010--D (Models 30603 and

30607).

REFER TO THE OPERATOR’S MANUAL FOR OPER-

ATING, MAINTENANCE AND ADJUSTMENT

INSTRUCTIONS. For reference, insert a copy of the

Operator’s Manual and Parts Catalog for your machine

into Chapter 2 of this service manual. Additional copies

of the Operator’s Manual and Parts Catalog are avail-

able on the internet at www .Toro.com.

The Toro Company reserves the right to change product

specifications or this publication without notice.

This safety symbol means DANGER, WARNING,

or CAUTION, PERSONAL SAFETY INSTRUC-

TION. When you see this symbol, carefully read

the instructions that follow. Failure to obey the

instructions may result in personal injury.

NOTE: A NOTE will give general information about the

correct operation, maintenance, service, testing or re-

pair of the machine.

IMPORTANT: The IMPORTANT notice will give im -

portant instructions which must be followed to pre-

vent damage to systems or components on the

machine.

E Th e Toro Company -- 2014

Groundsmaster 4000-- D

Groundsmaster 4000--D/4010--D

This page is intentionally blank.

Groundsmaster 4000--D/4010--D

Table Of Contents

Chapter 1 -- Safety

General Safety Instructions 1 -- 2..................

Jacking Instructions 1 -- 5.........................

Safety and Instruction Decals 1 -- 6................

Chapter 2 -- Product Records and Maintenance

Product Records 2 -- 1...........................

Maintenance 2 -- 1...............................

Equivalents and Conversions 2 -- 2................

Torque Specifications 2 -- 3.......................

Chapter 3 -- Y anmar Diesel Engine

Specifications 3 -- 2..............................

General Information 3 -- 5........................

Service and Repairs 3 -- 10.......................

YANMAR TNV (Tier 4i) SERIES SERVICE MANUAL

YANMAR TNV (T ier 4i) SERIES TROUBLE--

SHOOTING MANUAL

YANMAR TNV (Tier 4) SERIES SERVICE MANUAL

YANMAR TNV (Tier 4) SERIES TROUBLESHOOTING

MANUAL

Chapter 4 -- Hydraulic System

Specifications 4 -- 2..............................

General Information 4 -- 4........................

Hydraulic Schematic 4 -- 10.......................

Hydraulic Flow Diagrams 4 -- 12...................

Special Tools 4 -- 28.............................

T roubleshooting 4 -- 33...........................

Testi ng 4 -- 40...................................

Adjustments 4 -- 70..............................

Service and Repairs 4 -- 71.......................

SAUER--DANFOSS H1 CLOSED CIRCUIT AXIAL PIS-

TON PUMPS SERVICE MANUAL

SAUER--DANFOSS K and L FRAME VARIABLE MO-

TORS SERVICE MANUAL

EATON PARTS AND REPAIR INFORMATION: 5

SERIES STEERING CONTROL UNITS

Chapter 5 -- Electrical System

General Information 5 -- 2........................

Special Tools 5 -- 6..............................

InfoCenter Display 5 -- 8..........................

T roubleshooting 5 -- 15...........................

Adjustments 5 -- 25..............................

Electrical System Quick Checks 5 -- 29.............

Component Testing 5 -- 30........................

Service and Repairs 5 -- 63.......................

Chapter 6 -- Axles, Planetaries and Brakes

Specifications 6 -- 2..............................

General Information 6 -- 3........................

Adjustments 6 -- 4...............................

Service and Repairs 6 -- 6........................

Chapter 7 -- Chassis

General Information 7 -- 1........................

Service and Repairs 7 -- 2........................

Chapter 8 -- Cutting Decks

Specifications 8 -- 2..............................

General Information 8 -- 3........................

T roubleshooting 8 -- 4............................

Service and Repairs 8 -- 6........................

SafetyProduct Records

and Maintenance

Yanmar

Diesel Engine

Hydraulic

System

Electrical

System

Axles, Planetaries

and Brakes

Chassis

Cutting

Decks

Groundsmaster 4000--D/4010--D

This page is intentionally blank.

Groundsmaster 4000--D/4010--D

Table Of Contents (Continued)

Chapter 9 -- Operator Cab

General Information 9 -- 2........................

Service and Repairs 9 -- 3........................

SANDEN SD COMPRESSOR SERVICE GUIDE

Chapter 10 -- Foldout Drawings

Electrical Drawing Designations 10 -- 2.............

Hydraulic Schematic 10 -- 3.......................

Electrical Schematics 10 -- 4......................

Wire Harness Drawings 10 -- 9....................

OperatorFoldout

Drawings

Cab

Groundsmaster 4000--D/4010--D

This page is intentionally blank.

Groundsmaster 4000--D/4010--D Page 1 -- 1 Safety

Chapter 1

Safety

Table of Contents

GENERAL SAFETY INSTRUCTIONS 2............

Before Operating 2............................

While Operating 3............................

Maintenance and Service 4....................

JACKING INSTRUCTIONS 5.....................

SAFETY AND INSTRUCTION DECALS 6..........

Safety

Groundsmaster 4000--D/4010--DPage 1 -- 2Safety

General Safety Instructions

The Groundsmaster 4000-D and 4010--D are tested and

certified by Toro for compliance with existing safety

standards and specifications. Although hazard control

and accident prevention partially are dependent upon

the design and configuration of the machine, these fac-

tors are also dependent upon the awareness, concern

and proper training of the personnel involved in the op-

eration, transport, maintenance and storage of the ma-

chine. Improper use or maintenance of the machine can

result in injury or death. To reduce the potential for injury

or death, comply with the following safety instructions.

WARNING

To reduce the potential for injury or death, com-

ply with the following safety instructions.

Before Operating

1. Review and understand the contents of the Opera-

tor’s Manual and Operator’s DVD before starting and

operating the vehicle. Become familiar with the controls

and know how to stop the vehicle and engine quickly.

Additional copies of the Operator’s Manual are available

on the internet at www.Toro.com.

2. Keep all shields, safety devices and decals in place.

If a shield, safety device or decal is defective, illegible or

damaged, repair or replace it before operating the ma-

chine. Also tighten any loose nuts, bolts or screws to en-

sure machine is in safe operating condition.

3. Assure interlock switches are adjusted correctly so

engine cannot be started unless traction pedal is in

NEUTRAL and cutting decks are DISENGAGED.

4. Since diesel fuel is flammable, handle it carefully:

A. Useanapprovedfuelcontainer.

B. Do not remove fuel tank cap while engine is hot or

running.

C. Do not smoke while handling fuel.

D. Fill fuel tank outdoors and only to within an inch of

the top of the tank, not the filler neck. Do not overfill.

E. Wipe up any spilled fuel.

Groundsmaster 4000--D/4010--D Page 1 -- 3 Safety

While Operating

1. Sit on the seat when starting and operating the ma-

chine.

2. Before starting the engine:

A. Apply the parking brake.

B. Make sure traction pedal is in neutral and the

PTO switch is OFF (disengaged).

3. After engine is started, release parking brake and

keep foot off traction pedal. Machine must not move. If

movement is evident, there may be a problem with trac-

tion pedal calibration or the piston (traction) pump t hat

needs to be corrected before using the machine.

4. Do not run engine in a confined area without ade-

quate ventilation. Exhaust fumes are hazardous and

could possibly be deadly.

5. Do not touch engine, radiator or exhaust system

while engine is running or soon after it is stopped. These

areas could be hot enough to cause burns.

6. Before getting off the seat:

A. Ensure that traction pedal is in neutral.

B. Fully lower and disengage cutting decks. Wait for

blades to stop.

C. Apply the parking brake.

D. Stop engine and remove key from switch.

7. Toro recommends that a nytime the machine is

parked (short or long term), the cutting decks should be

lowered to the ground. This relieves hydraulic pressure

from the deck lift circuit and eliminates the risk of the cut-

ting decks unexpectedly lowering to the ground.

8. Do not park on slopes unless wheels are chocked or

blocked.

Safety

Groundsmaster 4000--D/4010--DPage 1 -- 4Safety

Maintenance and Service

1. Before servicing or making adjustments, lower

decks, stop engine, apply parking brake and remove

key from the ignition switch.

2. Make sure machine is in safe operating condition by

keeping all nuts, bolts and screws tight.

3. Never store the machine or fuel container inside

where there is an open flame, such as near a water heat-

er or furnace.

4. Make sure all hydraulic connectors are tight and all

hydraulic hoses and lines are in good condition before

applying pressure to the hydraulic system.

5. Keep body and hands away from pin hole leaks in hy-

draulic lines that eject high pressure hydraulic fluid. Use

cardboard or paper to find hydraulic leaks. Hydraulic

fluid escaping under pressure can penetrate skin and

cause injury. Fluid accidentally injected into the skin

must be surgically removed within a few hours by a doc-

tor familiar with this form of injury or gangrene may re-

sult.

6. Before disconnecting or performing any work on the

hydraulic system, all pressure in system must be re-

lieved by lowering cutting decks to the ground and stop-

ping engine.

7. If major repairs are ever needed or assistance is de-

sired, contact an Authorized Toro Distributor.

8. To reduce potential fire hazard, keep engine area

free of excessive grease, g rass, leaves and dirt. Clean

protective screen on machine frequently.

9. If engine must be running to perform maintenance or

an adjustment, keep hands, feet, clothing and other

parts of the body away from cutting decks and other

moving parts. Keep bystanders away.

10.To assure saf et y and accuracy, check maximum en-

gine speed.

11. Shut engine off before checking or adding oil to the

crankcase.

12.Disconnect battery before servicing the machine.

Disconnect n egative cable first and positive cable last.

If battery voltage is required for troubleshooting or test

procedures, temporarily connect the battery. Reconnect

positive cable first and negative cable last.

13.Battery acid is poisonous and can cause burns.

Avoid contact with skin, eyes and clothing. Protect your

face, eyes and clothing when working with a battery.

14.Battery gases can explode. Keep cigarettes, sparks

and flames away from the battery.

15.At the time of manufacture, the machine conformed

to the safety standards for riding mowers. To assure op-

timum performance and continued safety certification of

the machine, use genuine Toro replacement parts and

accessories. Replacement partsandaccessoriesmade

by other manufacturers may result in non-conformance

with the safety standards and the warranty may be

voided.

16.When changing attachments, tires or performing

other service, use correct supports, hoists and jacks.

Make sure machine is parkedonasolidlevelsurface

such as a concrete floor. Prior to raising the machine, re-

move any attachments that may interfere with the safe

and proper raising of the machine. Always chock or

block wheels. Use appropriate jack stands to support

the raised machine. If the machine is not properly sup-

ported by jack stands, the machine may move or fall,

which may result in personal injury (see Jacking Instruc-

tions in this chapter).

17.When welding on machine, disconnect all battery

cables to prevent damage to machine electronic equip-

ment. Disconnect negative battery cable first and posi-

tive cable last. Also, disconnect wire harness connector

from both of the TEC controllers, disconnect and re-

move the engine ECM and disconnect the terminal con-

nector from the alternator. Attach welder ground cable

no more than two (2) feet (0.6 meters) from the welding

location.

18.Make sure to dispose of potentially harmful waste

(e.g. fuel, oil, engine coolant, filters, battery) in an envir-

onmentally safe manner. Follow all local codes and reg-

ulations when recycling or disposing of waste.

Groundsmaster 4000--D/4010--D Page 1 -- 5 Safety

Jacking Instructions

CAUTION

When changing attachments, tires or perform-

ing other service, use correct jacks and sup-

ports. Make sure machine is parked on a solid,

level surface such as a concrete floor. Prior to

raising machine, remove any attachments that

may interfere with the safe and proper raising of

the machine. Always chock or block wheels. Use

jack stands to support the raised machine. If the

machine is not properly supported by jack

stands, the machine may move or fall, which

may result in personal injury.

Jacking the Front End (Fig. 1)

1. Set parking brake and chock both rear tires to pre-

vent the machine from moving.

2. Position jack securely under the frame, just to the in-

side of the front tire. Jack front wheel off the ground.

3. Once the machine is raised, position jack stand un-

der the frame as close to the wheel as possible to sup-

port the machine.

Jacking the Rear End (Fig. 2)

1. Set parking brake and chock both front tires to pre-

vent the machine from moving.

2. Place jack securely under the center of rear axle.

Jack rear of machine off the ground.

3. Once the machine is raised, use jack stands under

the axle to support the machine.

1. Front jacking point 2. Front tire

Figure 1

1

2

1

1. Rear axle jacking point 2. Rear tire

Figure 2

1

2

Safety

Groundsmaster 4000--D/4010--DPage 1 -- 6Safety

Safety and Instruction Decals

Numerous safety and instruction decals are affixed to

your Groundsmaster machine. If any decal becomes il-

legible or damaged, install a new decal. Decal part num-

bers are listed in your Parts Catalog.

Groundsmaster 4000--D/4010--D Page 2 -- 1 Product Records and Maintenance

Chapter 2

Product Records and Maintenance

Table of Contents

PRODUCT RECORDS 1.........................

MAINTENANCE 1..............................

EQUIVALENTS AND CONVERSIONS 2...........

Decimal and Millimeter Equivalents 2............

U.S. to Metric Conversions 2...................

TORQUE SPECIFICATIONS 3...................

Fastener Identification 3.......................

Using a Torque Wrench with an Offset Wrench 3..

Standard Torque for Dry, Zinc Plated and

Steel Fasteners (Inch Series) 4...............

Standard Torque for Dry, Zinc Plated and

Steel Fasteners (Metric) 5....................

Other Torque Specifications 6..................

Conversion Factors 6.........................

Product Records

Insert Operator’s Manuals and Parts Catalogs for your

Groundsmaster at the end of this chapter. Additionally,

if any optional equipment or accessories have been

installed to your machine, insert the Installation Instruc-

tions, Operator’s Manuals and Parts Catalogs for those

options at the end of this chapter.

Maintenance

Maintenance procedures and recommended service in-

tervals for your Groundsmaster are covered in the Oper-

ator’s Manual. Refer to that publication when performing

regular equipment maintenance.

Product Records

and Maintenance

0.09375

Groundsmaster 4000--D/4010--DPage 2 -- 2Product Records and Maintenance

Equivalents and Conversions

Groundsmaster 4000--D/4010--D Page 2 -- 3 Product Records and Maintenance

Torque Specifications

Recommended fastener torque values are listed in the

following tables. For critical applications, as determined

by Toro, either the recommended torque or a torque that

is unique to the application is clearly identified and spe-

cified in this Service Manual.

These Torque Specifications for the installation and

tightening of fasteners shall apply to all fasteners which

do not have a specific requirement identified in this Ser-

vice Manual. The following factors shall be considered

when applying torque: cleanliness of the fastener, use

of a thread sealant (e.g. Loctite), degree of lubrication

on the fastener, presence of a prevailing torque feature

(e.g. Nylock nut), hardness of the surface underneath

the f astener’s h ead or similar condition which affects the

installation.

As noted in the following tables, torque values should be

reduced by 25% for lubricated fasteners to achieve

the similar stress as a dry fastener. Torque values may

also have to be reduced when the fastener is threaded

into aluminum or brass. The specific torque value

should be determined based on the aluminum or brass

material strength, fastener size, length of thread en-

gagement, etc.

The standard method of verifying torque shall be per-

formed by marking a line on the fastener (head or nut)

and mating part, then back off fastener 1/4 of a turn.

Measure the torque required to tighten the fastener until

thelinesmatchup.

Fastener Identification

Figure 1

Grade 1 Grade 5 Grade 8

Inch Series Bolts and Screws

Figure 2

Class 8.8 Class 10.9

Metric Bolts and Screws

Using a Torque Wrench with an Offset Wrench

Use of an offset wrench (e.g. crowfoot wrench) will affect

torque wrench calibration due to the effective change of

torque wrench length. When using a torque wrench with

an offset wrench, multiply the listed torque recommen-

dation by the calculated torque conversion factor (Fig.

3) to determine proper tightening torque. Tightening

torque when using a torque wrench with an offset

wrench will be lower than the listed torque recommen-

dation.

Example: The measured effective length of the torque

wrench (distance from the center of the handle to the

center of the square drive) is 18”.

The measured effective length of the t orque wrench with

the offset wrench installed (distance from the center of

the handle to the center of the offset wrench) is 19”.

The calculated torque conversion factor for this torque

wrench with this offset wrench would be 18 / 19 = 0.947.

If the listed torque recommendation for a fastener is

from 76 to 94 ft--lb, the proper torque when using this

torque wrench with an offset wrench would be from 72

to 89 ft--lb.

Figure 3

(effective length of

torque wrench)

TORQUE CONVERSION FACTOR = A / B

A

B

(effective l ength of torque

Torque wrenchOffset wrench

wrench + offset wrench)

Product Records

and Maintenance

Groundsmaster 4000--D/4010--DPage 2 -- 4Product Records and Maintenance

Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series)

Thread Size

Grade 1, 5 &

8withThin

Height Nuts

SAE Grade 1 Bolts, Screws, Studs &

Sems with Regular Height Nuts

(SAE J995 Grade 2 or Stronger Nuts)

SAE Grade 5 Bolts, Screws, Studs &

Sems with Regular Height Nuts

(SAE J995 Grade 2 or Stronger Nuts)

SAE Grade 8 Bolts, Screws, Studs &

Sems with Regular Height Nuts

(SAE J995 Grade 5 or Stronger Nuts)

in--lb in--lb N--cm in--lb N--cm in--lb N--cm

#6--32UNC

10 + 2 13 + 2 147 + 23

15 + 2 169 + 23 23 + 3 262 + 34

#6--40UNF 17 + 2 192 + 23 25 + 3 282 + 34

#8--32UNC

13 + 2 25 + 5 282 + 30

29 + 3 328 + 34 41 + 5 463 + 56

#8--36UNF 31 + 4 350 + 45 43 + 5 486 + 56

#10--24UNC

18 + 2 30 + 5 339 + 56

42 + 5 475 + 56 60 + 6 678 + 68

#10--32UNF 48 + 5 542 + 56 68 + 7 768 + 79

1/4 -- 20 UNC 48 + 7 53 + 7 599 + 79 100 + 10 1130 + 113 140 + 15 1582 + 169

1/4 -- 28 UNF 53 + 7 65 + 10 734 + 113 115 + 12 1299 + 136 160 + 17 1808 + 192

5/16 -- 18 UNC 115 + 15 105 + 15 1186 + 169 200 + 25 2260 + 282 300 + 30 3390 + 339

5/16 -- 24 UNF 138 + 17 128 + 17 1446 + 192 225 + 25 2542 + 282 325 + 33 3672 + 373

ft--lb ft--lb N--m ft--lb N--m ft--lb N--m

3/8 -- 16 UNC 16 + 2 16 + 2 22 + 3 30 + 3 41 + 4 43 + 5 58 + 7

3/8 -- 24 UNF 17 + 2 18 + 2 24 + 3 35 + 4 47 + 5 50 + 6 68 + 8

7/16 -- 14 UNC 27 + 3 27 + 3 37 + 4 50 + 5 68 + 7 70 + 7 95 + 9

7/16 -- 20 UNF 29 + 3 29 + 3 39 + 4 55 + 6 75 + 8 77 + 8 104 + 11

1/2 -- 13 UNC 30 + 3 48 + 7 65 + 9 75 + 8 102 + 11 105 + 11 142 + 15

1/2 -- 20 UNF 32 + 4 53 + 7 72 + 9 85 + 9 115 + 12 120 + 12 163 + 16

5/8 -- 1 1 UNC 65 + 10 88 + 12 119 + 16 150 + 15 203 + 20 210 + 21 285 + 28

5/8 -- 18 UNF 75 + 10 95 + 15 129 + 20 170 + 18 230 + 24 240 + 24 325 + 33

3/4 -- 10 UNC 93 + 12 140 + 20 190 + 27 265 + 27 359 + 37 375 + 38 508 + 52

3/4 -- 16 UNF 115 + 15 165 + 25 224 + 34 300 + 30 407 + 41 420 + 43 569 + 58

7/8 -- 9 UNC 140 + 20 225 + 25 305 + 34 430 + 45 583 + 61 600 + 60 813 + 81

7/8 -- 14 UNF 155 + 25 260 + 30 353 + 41 475 + 48 644 + 65 667 + 66 904 + 89

NOTE: Reduce torque values listed in the table above

by 25% for lubricated fasteners. Lubricated fasteners

are defined as threads coated with a lubricant such as

engine oil or thread sealant such as Loctite.

NOTE: Torque values may have to be reduced when

installing fasteners into threaded aluminum or brass.

The specific torque value should be determined based

on the fastener size, the aluminum or base material

strength, length of thread engagement, etc.

NOTE: The nominal torque values listed above for

Grade 5 and 8 fasteners are based on 75% of the mini-

mum proof load specified in SAE J429. The tolerance is

approximately +

10% of the nominal torque value. Thin

height nuts include jam nuts.

Groundsmaster 4000--D/4010--D Page 2 -- 5 Product Records and Maintenance

Standard Torque f or Dry, Zinc Plated and Steel Fasteners (Metric Series)

Thread Size

Class 8.8 Bolts, Screws and Studs with

Regular Height Nuts

(Class 8 or Stronger Nuts)

Class 10.9 Bolts, Screws and Studs with

Regular Height Nuts

(Class 10 or Stronger Nuts)

M5 X 0.8 57 + 6in--lb 644 + 68 N--cm 78 + 8in--lb 881 + 90 N--cm

M6 X 1.0 96 + 10 in--lb 1085 + 113 N --cm 133 + 14 in--lb 1503 + 158 N--cm

M8 X 1.25 19 + 2ft--lb 26 + 3N--m 28 + 3ft--lb 38 + 4N--m

M10 X 1.5 38 + 4ft--lb 52 + 5N--m 54 + 6ft--lb 73 + 8N--m

M12 X 1.75 66 + 7ft--lb 90 + 10 N-- m 93 + 10 ft--lb 126 + 14 N-- m

M16 X 2.0 166 + 17 ft--lb 225 + 23 N--m 229 + 23 ft--lb 310 + 31 N--m

M20 X 2.5 325 + 33 ft--lb 440 + 45 N--m 450 + 46 ft--lb 610 + 62 N--m

NOTE: Reduce torque values listed in the table above

by 25% for lubricated fasteners. Lubricated fasteners

are defined as threads coated with a lubricant such as

engine oil or thread sealant such as Loctite.

NOTE: Torque values may have to be reduced when

installing fasteners into threaded aluminum or brass.

The specific torque value should be determined based

on the fastener size, the aluminum or base material

strength, length of thread engagement, etc.

NOTE: The nominal torque values listed above are

based on 75% of the minimum proof load specified in

SAE J1199. The tolerance is approximately +

10% of the

nominal torque value.

Product Records

and Maintenance

Groundsmaster 4000--D/4010--DPage 2 -- 6Product Records and Maintenance

Other Torque Specifications

SAE Grade 8 Steel Set Screws

Thread Size

Recommended Torque

Square Head Hex Socket

1/4 -- 20 UNC 140 + 20 in--lb 73 + 12 in--lb

5/16 -- 18 UNC 215 + 35 in--lb 145 + 20 in--lb

3/8 -- 16 UNC 35 + 10 ft--lb 18 + 3ft--lb

1/2 -- 13 UNC 75 + 15 ft--lb 50 + 10 ft--lb

Thread Cutting Screws

(Zinc Plated Steel)

Type 1, Type 23 or Type F

Thread Size Baseline Torque*

No. 6 -- 32 UNC 20 + 5in--lb

No. 8 -- 32 UNC 30 + 5in--lb

No. 10 -- 24 UNC 38 + 7in--lb

1/4 -- 20 UNC 85 + 15 in--lb

5/16 -- 18 UNC 110 + 20 in--lb

3/8 -- 16 UNC 200 + 100 in--lb

Wheel Bolts and Lug Nuts

Thread Size

Recommended Torque**

7/16 -- 20 UNF

Grade 5

65 + 10 ft--lb 88 + 14 N --m

1/2 -- 20 UNF

Grade 5

80 + 10 ft--lb 108 + 14 N--m

M12 X 1.25

Class 8.8

80 + 10 ft--lb 108 + 14 N--m

M12 X 1.5

Class 8.8

80 + 10 ft--lb 108 + 14 N--m

** For steel wheels and non--lubricated fasteners.

Thread Cutting Screws

(Zinc Plated Steel)

Thread

Size

Threads per Inch

Baseline Torque*

Type A Type B

No. 6 18 20 20 + 5in--lb

No. 8 15 18 30 + 5in--lb

No. 10 12 16 38 + 7in--lb

No. 12 11 14 85 + 15 in--lb

* Hole size, material strength, material thickness and fin-

ish must be considered when determining specific

torque values. All torque values are based on non--lubri-

cated fas teners.

Conversion Factors

in--lb X 11.2985 = N--cm N--cm X 0.08851 = in--lb

ft--lb X 1.3558 = N--m N--m X 0.7376 = ft--lb

Groundsmaster 4000--D/4010--D Page 3 -- 1 Yanmar Diesel Engine

Chapter 3

Yanmar Diesel Engine

Table of Contents

SPECIFICATIONS 2............................

Models 30603 and 30605 2....................

Models 30607 and 30609 3....................

GENERAL INFORMATION 5.....................

Operator ’s Manuals 5.........................

Yanmar Service and Troubleshooting Manuals 5..

Stopping the Engine 5.........................

Engine Electronic Control Unit (ECU) 6..........

Yanmar Engine: Models 30603 and 30605 7.....

Yanmar Engine: Models 30607 and 30609 8.....

SERVICE AND REPAIRS 10.....................

Air Cleaner System 10.........................

Fuel System 12...............................

Check Fuel Lines and Connections 13.........

Empty and Clean Fuel Tank 13................

Priming the Fuel System 13...................

Fuel Tank Removal 13.......................

Fuel Tank Installation 13......................

Radiator and Oil Cooler Assembly 14............

Engine 18....................................

Engine Removal 19..........................

Engine Installation 21........................

Spring Coupler 24............................

Exhaust System (Models 30607 and 30609) 26...

YANMAR TNV (Tier 4i) SERIES SERVICE MANUAL

YANMAR TNV (Tier 4i) SERIES TROUBLESHOOTING

MANUAL

YANMAR TNV (Tier 4) SERIES SERVICE MANUAL

YANMAR TNV (Tier 4) SERIES TROUBLESHOOTING

MANUAL

Yanmar

Diesel Engine

Groundsmaster 4000--D/4010--DPage 3 -- 2Yanmar Diesel Engine

Specifications (Models 30603 and 30605)

Item Description

Make / Designation Yanmar Model 4TNV84T--ZMTR: 4--Cycle, 4 Cylinder,

Water Cooled, Turbocharged, Tier 4i Diesel Engine

Bore 3.307 in (84 mm)

Stroke 3.543 in (90 mm)

Total Displacement 121.7 in

3

(1995 c c)

Firing Order 1 (closest to flywheel end) -- 3 -- 4 (farthest from flywheel) -- 2

Direction of Rotation Counterclockwise (viewed from flywheel)

Fuel Diesel or Biodiesel (up to B20) Fuel with Low or

Ultra Low Sulfur Content

Fuel Tank Capacity 21 U.S. gallons (79.5 liters)

Fuel Injection Pump Yanmar MP2 Distributor Type Pump

Fuel Injection Type Direct Injection

Starting Aid Intake Air Heater

Governor Electronic All Speed

Low Idle (no load) 1200 R PM

High Idle (no load) 2600 RPM

Engine Oil API CH--4, CI--4 or higher

Engine Oil Viscosity See Operator’s Manual

Crankcase Oil Capacity 6 U.S. quarts (5.7 liters) with Filter

Oil Pump T rochoid Type

Coolant Capacity

Groundsmaster 4000--D (Model 30605) 9 U.S. quarts (8.5 liters)

Groundsmaster 4010--D (Model 30603) 14.5 U.S. quarts (13.7 liters)

Alternator/Regulator 12 VDC, 80 amp

Engine Weight (Dry) 375 U.S. pounds (170 kg)

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